CN1988947B - Process for making media for use in air/oil separators - Google Patents

Abstract

Techniques are described, for preparing media arrangements having resin provided from an aqueous based resin system therein. The media generally comprises fibers configured in a non-woven matrix. Preferred resin arrangements, and conditions for resin application, drying and cure are provided. Also described are media containing arrangements including media made according to the preferred descriptions.

Description

Manufacturing is used for the method for gas/oil eliminator medium

Cross reference to related application

The application and some modifications thereof and increase comprise that the applying date is the disclosure of the U.S. Provisional Application 60/577,067 on June 4th, 2004.60/577,067 disclosure is incorporated into this paper at this.In addition, the application requires the priority of application 60/577,067 with suitable degree.

Technical field

The present invention relates to can be used for the medium of gas/oil eliminator, for example, the level of condensing, discharging level or both.Specifically, the present invention relates to this medium that the aqueous slurry by fiber forms, use the water-based resin system between fiber, to provide bonding.The invention still further relates to the gas/oil eliminator and the formation method that comprise this medium.

Background technology

Known various gas/oil separator structure.Some structures are disclosed in, for example, in the following document, wherein each following document all in full form be incorporated into this paper: US 5,605,555; 6,093,231; 6,136,076; 6,485,535; With PCT application US03/40691, the applying date is on December 17th, 2003.

Generally, described separator comprises media stage, and it comprises non-woven fiber material.Common described structure comprises condense grade medium and discharging level medium.At least condense grade medium sometimes by with the fiber applications of aqueous fibre mud on axle, by vacuum draw, form in the mode that forms medium bag (medium of shaping).Finally, the resin impregnated that is solidified of medium bag.

In a lot of systems, described resin structure in most of the cases, is acetone from organic solvent system, methyl iso-butyl ketone (MIBK) (MIBK), methyl alcohol, the various mixtures of isopropyl alcohol and/or dibasic ester.A kind of common technology comprises by dissolving or letdown resin generation mud in solvent, so that resin infiltrates through medium easily.Soaking into is that medium by being shaped is immersed in the resin/solvent solution of drum, for example about 5 minutes, finishes.The medium that will soak into shifts out and drainage then, for example reaches 12 hours, so that remove excessive resin from medium holes.Because low vapor pressure, the ratio of solvent and resin gel evaporates rapidly.This makes the rate of film build of medium holes reduce to minimum.Though described technology has produced good final dielectric structure, described process steam has also produced fire, health and environmental problem.

Generally, wish to use instead water based systems, to avoid in technical process with an organic solvent.Some methods of doing like this are disclosed in, for example, the applying date is the U.S. Provisional Application 60/460 on April 4th, 2003,375, and it is that the PCT application of submitting on April 2nd, 2004 requires priority that this application is applied day, the title of this PCT application is " comprising the filter medium (Filter Media Preparedin Aqueous System Including Resin Binder) for preparing in the aqueous system of resin binder ", and is open with publication number WO04/089509 now.Whole disclosures of described provisional application and PCT application are incorporated into this paper at this.

Wish to improve the water based systems that is used to soak into technology, wherein the medium of Cheng Xinging is immersed in the water-based resin system and is soaked into by the water-based resin system, forms adhesive system subsequently in fiber base.

Summary of the invention

In this article, described the technology that is used to generate based on the matrix of fiber, the resin that is provided by water based systems is provided described fibrous matrix.The matrix that is produced can be used as gas-liquid separator, for example the media stage in gas/oil eliminator.

Described technology relates generally to: the preferred water-based resin that (a) is used for described technology; (b) be used for resin-bonded is gone into the optimum condition of matrix.An effect using preferred material as herein described and technology is not have the resin creep or the migration of unacceptable degree in the matrix of formation.

To the management of resin transfer in the fibrous matrix, make it to be lower than unacceptable level, part relates to before the hardening of resin, from the resin condition of aqueous system loading and the condition of dewatering from resin system (condensing with resin).This paper has described preferred condition and various resin.

This paper has also described and has comprised at least one gas-liquid separator according to the media stage of described technology formation; With its using method.

This paper has described multiple technologies and condition.Do not need to satisfy all conditions as herein described, to improve material and technology according to the present invention.

Description of drawings

Fig. 1 is according to the plan view from above that the present invention includes the gas/oil eliminator of media stage.

Fig. 2 is the schematic sectional view along Fig. 1 center line 2-2.

Fig. 3 is the schematically local figure of the amplification of part among Fig. 2.

The specific embodiment

I. confirm that the water-based resin system disclosed principle of this paper relates in part under the situation of not using a large amount of organic solvents, confirm to generate the optimum condition that can be used for fiber medium in gas/oil separator device.The optimum condition of being confirmed is according to using some existing water-based resin system to obtain, although can use other resin system.The resin of being assessed comprises following type:

A. water-based emulsion;

B. water-based polyurethane dispersion;

C. water-based epoxy resin;

D. water based phenolic resin.

A. water-based emulsion

Available water-based emulsion includes, but is not limited to the water-based emulsion from following supplier's following type:

1.Acronal S 888S, S 886 and NX 5818, they are to purchase (Charlotte, the styrene-acrylonitrile copolymer hydrochlorate polymer of BASF AG NC) in North Carolina state Xia Luote.

2.Acronal 2348, adopt the alternative polycarboxylic acid solution of polyalcohol as the crosslinking agent preparation, can purchase (Charlotte, BASF AG NC) in North Carolina state Xia Luote.

3.Acrodur 950L comprises the modification polycarboxylic acid copolymer of polyhydroxy-alcohol crosslinking agent, from North Carolina state Xia Luote (Charlotte, BASF AG NC).

4.Carboset GA 1087, a kind of styrene acrylic copolymer emulsion is from joslyn hi-voltage (Cleveland, Noveon company OH).

5.Carboset GA 1166, a kind of acrylic acid dispersion is from joslyn hi-voltage (Cleveland, Noveon company OH).

6.Carbocure TSR-72, a kind of acrylic acid dispersion is from joslyn hi-voltage (Cleveland, Noveon company OH).

7.PD 2085-A2, the mixture of a kind of acrylic acid and urethanes emulsion can be purchased (St.Paul, H.B.Fuller company MN) in Sao Paulo, the Minnesota State.

8.PD-8176 a kind of self-crosslinking acrylic latex can be purchased (St.Paul, H.B.Fuller company MN) in Sao Paulo, the Minnesota State.

9.PD 3808, PD 2045-H and 3160K all are acrylic based emulsion, can purchase (St.Paul, H.B.Fuller company MN) in Sao Paulo, the Minnesota State.

10.NF-3 a kind of synthetic polymer can be purchased (St.Paul, H.B.Fuller company MN) in Sao Paulo, the Minnesota State.

11.Airflex 4530 and 810, acrylic based emulsion is from Air Products of Allentown, PA (Pennsylvania).

Other two kinds of available acrylic acid solutions are NF-4 and PD-0466, and the both can purchase the company in H.BFuller.NF-4 is carboxyl and the self-crosslinking acrylic solution polymer of hydroxyl in water, and it has 100 ℃ of Tg, and it is shaped 200 ℃ of thermosettings.PD-0466 is the self-crosslinking formaldehyde-free acrylic based emulsion of acrylic and epoxide functional groups, solid-stately has 41 ℃ of Tg and the pH value is 3.0 42%.It can be crosslinked fully at 130 ℃.

B. dispersions of polyurethanes

Generally has the polyurethane that two families can use; That is, aliphatic and aromatic series.Aliphatic polyurethane mainly is polyester and/or acrylic acid phenol also based on based on aliphatic isocyanates in order (for example HPI and IPDI) normally.Aromatic urethane mainly is a polyether polyol also based on the polyurethane of aromatic series isocyanates (for example MDI and TDI) normally.

Available water-based polyurethane includes, but is not limited to following every:

1.Sancure 2715, based on the carboxylation urethanes polymeric dispersions of polyethers, from Noveon, Cleveland, OH (the Noveon company of joslyn hi-voltage).

2.Sancure 13077, based on the carboxylation urethane ester dispersion of polyester, from Noveon, Cleveland, OH (the Noveon company of joslyn hi-voltage).

3.Solucote 1087 and 1012, dispersions of polyurethanes, from SOLUOL Chemical, Co., West Warwick, RI.

4.Witcobond W-290HSC, W-296 and W-320, every kind all is aliphatic polyurethane dispersions, from Crompton Corp.-Uniroyal Chemicals, Middlebury, CT (Connecticut State).

5.PD 4009,4044 and 2104, they are aqueous polyurethane dispersions, from H.B.Fuller, and St.Paul, MN (Sao Paulo, the Minnesota State).

C. water-based epoxy resin

Available water-based epoxy resin includes, but is not limited to following every:

1.Waterborne EPI-REZ Resins 3510-W-60,3515-W-60 and 3519-W-50, every kind from Shell Chemical, Houston, TX (Texas Houston), and sell by ResolutionPerformance Chemical.

2.PN 2072T4, epoxy resin derivant, from H.B.Fuller, St.Paul, MN (Sao Paulo, the Minnesota State).

D. phenolic resins

Phenolic resins generally is phenol formaldehyde resin, urea aldehyde and melamino-formaldehyde resin.Phenol formaldehyde resin has two kinds of main commercial resin systems, i.e. Resoles (first rank phenolic resin) and Novolacs (novolaks).Resoles (first rank phenolic resin) obtains by phenol and formaldehyde are reacted under alkali condition, and wherein formaldehyde Pyrogentisinic Acid's mol ratio is greater than 1.Novolacs (novolaks) obtains by phenol and formaldehyde are reacted under acid condition, and wherein the mol ratio of phenol PARA FORMALDEHYDE PRILLS(91,95) is greater than 1.

Available phenolic resins includes, but is not limited to following every:

1.Resi-Mat GP 2928,2948 and 2981, from Georgia Pacific Resin, Inc., Decatur, GA (Georgia State).

2.GP 235 G10 are from Georgia Pacific Resin Inc., Decatur, GA (Georgia State).

3.AROFENE DR 520,571, T2155-W-55 and AROTAP R-1-W-150, and from Ashland Chemical Co., Columbus, OH (Ohio).

Selected resin finally is the problem of selecting, and considers according to available cost and processing.General phenolic resins is the most cheap, and this factor is desirable.Yet, from phenolic resins, can discharge the not free phenol of extend of hope, cause environmental problem.

Can purchase the synthetic polymer NF-3 in H.B.Fuller company, NF-4 and PD-0466 can be used to substituted phenolic resin in some commercial Application, because they do not have formaldehyde to discharge.

Generally, the epoxy resin that does not discharge phenol and formaldehyde can be optional resin.Yet the resin of many other appointments of epoxy resin contrast is relatively costly usually.

I. use the technology of soaking into of latex or polyurethane

A. the dielectric matrix that is shaped is soaked into the water-based resin system of technology.

Usually, resin receives and is diluted to 2-10% (5-10% usually) solids content by weight from manufacturer/suppliers water.The solids content of resin can be by using before the dilution, and for example by Mettler-Toledo ofToledo, the moisture analyzer that Ohio (Ohio) makes is determined.In addition, it can be determined according to following process:

1. weigh commercial solution sample to obtain " wet sample weight ".

2. in heating furnace, sample is become dry, up to drying up all liq with 150 ℃.The dry sample of weighing is originally to obtain " dry sample weight ".

3. calculate solids content in the undiluted resin according to following formula:

Solids content (%)=(dry sample weight/wet sample weight) x100

In case known supplier provides the resin content of material, it can be used to determine to use how much water to generate 2-10% (being generally 5-10%) solids content synthetic, is used to soak into technology.As the commercialization supply, resin obtains in the mode of solution usually, has the nonvolatile resin content of 21-65%.

Use following technology, resin is provided in the dielectric matrix of shaping.Usually, after soaking into technology, by weight resin content is approximately 4-20% in the dielectric matrix of shaping.(that is, approximately the dielectric matrix of the final resin loading of 4-20% comprises resin or cured resin.)

Although other schemes are feasible, can provide available vacuum draw, aspirate the volume of about 550 cubic feet (CFM) with 28 Inches Of Mercury per minutes by pump, promptly be 15.6 cubic metres under 0.95Bar pressure.In order to control the amount of resin of passing medium, can be on vacuum pipeline mounted valve, to regulate flow.Valve openings, in certain embodiments, ratio is 1-100%, and by opening being set between 1-20%, the resin content that can obtain in medium is 1-60%, by weight.

B. use the method for soaking into technology of latex and polyurethane resin

1. only submergence.

By the dielectric matrix (medium of shaping) that following characteristics is made, be immersed in the solution about 5 minutes fully.Then it is shifted out and shelves with draining.At last, with its heat treatment with cured resin.

Generally, this method is not preferred, because reach soaking into the required temperature of pressure and will being higher than the required temperature of gel point that reaches latex resin of water, so moisture content has just been surpassed the critical film-forming temperature of resin before the evaporation fully.Therefore, before moisture content was evaporated fully, resin film covers also attempted the sealing medium hole.This is undesirable, because the obstruction in hole can reduce the desirability of fibrous matrix as gas/oil eliminator medium parts.

Only medium was immersed in the aqueous solution 5 minutes, another problem that shifts out then with draining is that water can make deformation of media in drainage procedure.This is known as medium " sagging " at this paper sometimes.

2. make resin system suction passing through medium by vacuum draw; The heating furnace drying.

In order to reduce the cycle of possibility sagging, and the formation of block film, replacement was immersed in solution 5 minutes with medium, medium is immersed in the resin solution and: (a) under the help of above-mentioned vacuum source, pump resin solution by the medium (under the vacuum draw effect) that is shaped at least about 10 seconds (for example in the 10-200 time range of second).Described medium shifts out from solution then, and other at least 10 seconds of vacuum source continuation effect (for example 10-200 second).This will discharge excessive resin solution from the medium bag apace, and stop sagging.The resin that soaks into preferably places then and is lower than 120 ℃ heating furnace, is generally 80 ℃-110 ℃, and with the evaporation moisture content and the not solidified resin that condenses, the available time is at least 45 minutes, but other condition is feasible.The medium bag of Bian Ganing is subjected to higher furnace temperature then, so that hardening of resin is generally at least 115 ℃, and often at least 150 ℃, for example 150 ℃-180 ℃, place a period of time that is enough to make hardening of resin, be generally a few minutes at least, often be 0.5-3 hour.

When this technology is used, usually: (a) latex solution comprises various acrylic resins, vinyl acetate, the dispersion of vinylacrylic acid ester; (b) polyurethane tends to migration in drying/coagulation step.Have duricrust on the outer surface of the normally resultant medium bag of its result, and owing to the loss of this position resin causes soft relatively center.

3. resin impregnated is used the vacuum draw step; Drying at room temperature.

In this method, resin solution is also under the help of vacuum source, be drawn through the time of the about 5-300 of medium bag second of shaping, and described medium bag is moved out of from the submergence of water based systems subsequently, and other at least 10 seconds of vacuum source continuation effect (be generally 10-200 second), with from the excessive resin of medium bag suction.The medium bag that soaks into is placed on the frame that is in room temperature subsequently, with the dry and resin that condenses, common 24 hours, although the time can change.The medium bag is placed in the stove and solidifies then, usually in 110 ℃-180 ℃ temperature range, and passes through time of a few minutes to 3 hour usually, although setting time can change.

Generally, when carrying out this technology, if sample after drying steps and before coagulation step with cross-sectional slices, can be observed quite few resin transfer, if any.If check that after coagulation step observable resin transfer significantly reduces (comparing with technology #2 above), styrene butyl diene latex especially, and some acetate, acrylic acid and polyurethane.

But, from some acrylic resin, the latex of the dispersion of vinyl acetate and vinylacrylic acid ester still tends to migration, to form the dura mater shell from the teeth outwards.Can suppose that the successful amount of avoiding moving depends on the employed specific surfactant in their commercial composition by the resin formula designer.

Tend to still have some not GA 1166HS of the migration of extend of hope: Noveon when the drying at room temperature from following supplier's following resin; The Airflex 4530 and 810 of Air Products; The PD 8176 of H.B.Fuller; S88S and NX 5818 with BASF.Other latex in the above-mentioned water-based emulsion tabulation does not demonstrate the not migration of extend of hope when at room temperature dry.

4. vacuum draw is to soak into medium; Dry under the temperature conditions that reduces.

In the method, resin solution be similar to the above-mentioned the 2nd and the mode of the 3rd part process be loaded into fibrous matrix, by at least 5 seconds suctions (be generally 5-300 second), medium shifts out from solution and continues vacuum draw a period of time then, often at least about 10 seconds (be generally 10-200 second), to reduce excessive resinous principle.Medium after soaking into is dry under the temperature that reduces then, in being not more than 10 ℃ environment, preferably is not more than 0 ℃, and for example in-7 ℃ to-18 ℃ temperature range, passing through is enough to one period drying time that resin is condensed, is at least usually 12 hours.Sample is placed in room temperature then, at least 1 hour usually, then in curing oven with 110 ℃-180 ℃ a period of times that placement is enough to solidify, place at least a few minutes up to 5 hours at least 150 ℃ usually.

By this method, specified resin is not observed film forming, and does not have obvious visible migration.

In order to simplify the range estimation of resin transfer, can before soaking into described medium, in solution, use color dye.The cross section of medium is represented concentrated intrasystem ad-hoc location, the normally dielectric surface of occurring in of migration dyeing.

C. be used for the method that water-based epoxy resin and phenolic resins soak into technology

1. general background

Generally, epoxy resin is diluted to latex and polyurethane with phenolic resins has identical solids content, i.e. 2-10% (5-10% usually) solids content.Curing agent is added in the epoxy resin solution, and wherein the solid portion of curing agent is 1 to the weight ratio of resin part: 100-20: 100.Tested curing agent has reduced the gelling time in the epoxy resin.Evaluated curing agent is by the aliphatic amine of Shell Chemical and HuntsmanChemicals supply and cycloaliphatic amines with by Sachem of Austin, the four butyl bromation amine (TBAB) that Texas (Texas) provides.

The curing agent of employed Shell Chemical is EPI-CURE 3295, a kind of low viscosity aliphatic amine complex compound.

Evaluated epoxy resin is EPI-REZ Resin 3510-W-60; EPI-REZ Resin3515-W-60; With EPI-REZ Resin 3519-W-50, all from Shell Chemical.

Phenolic aldehyde solution is without curing agent.When using in technology, they are diluted to the ratio identical with latex usually, i.e. the 5-10% solids content

(a) soak into and the heating furnace drying with vacuum draw.

Above B.2. in the process conditions described be used to epoxy resin and phenolic resins.There are not tangible film forming or migration.Phenolic resins tends to produce the residual smell of phenol formaldehyde resin.

(b) vacuum draw is to soak into described medium; Dry under the temperature of room temperature or reduction.

Epoxy resin solution and phenolic resins be used in as above-mentioned B.3. with B.4. as described in the identical method.There are not tangible resin film forming or migration.Phenolic resins produces the residual smell of phenol formaldehyde resin.

2. about the further discussion of water-based epoxy resin

Usually select the water-based epoxy resin system for use.They show favorable chemical resistance and solvent resistance.Preferably, used water-based epoxy resin is formaldehydeless (that is, according to the gross weight of solid, containing the formaldehyde greater than 0.001% by weight).Preferably, epoxy resin has higher glass transition temperature (Tg), common Tg＞100 ℃.

Usually the kind of available water-based epoxy resin is the epoxy resin of choosing from following group, and described group mainly comprises: the dispersion of liquid B isphenol A (bisphenol-A) epoxy resin; The dispersion of urethane-modified Bisphenol A (bisphenol-A) epoxy resin; The dispersion of epoxidised o-cresols novolac resin (epoxidized o-cresylic novolac resin); The dispersion of the epoxy resin of CTBN (butadiene-acrylonitrile) modification; And composition thereof.Every kind can be prepared into the pH value and be 2-11.This resin mixes with a spot of curing agent then, normally water miscible or water-soluble amine based compound or bromide-based compound.These compounds can be, for example, and aliphatic amine complex compound, the ring grease amine of modification, amide amine or 4-butyl amine bromide (TBAB).

The epoxy resin of the Shell company of above-mentioned appointment is available and satisfactory.

For water-based epoxy resin, usually after epoxy resin being loaded into axle or other structure with vacuum draw, the element that comprises fibrous material and last epoxy resin thereof is taken out from solution, and makes the air at room temperature suction pass described medium at least 20 seconds under the vacuum draw effect.Make described medium drying then, usually under 100 ℃, at least 1 hour.Carry out coagulation step, usually at 150 ℃, at least 15 minutes (0.25 hour).

III. be formed for the general technology of the medium of gas/oil separator system

According to the conventional method that above-mentioned part ii characterized, developed the following general technology that is formed for the shaping medium bag of gas/oil eliminator.

The dielectric matrix of moulding is generally prepared by the water slurry of fiber, normally glass fibre, for example borosilicate glass fiber.Described suspension generally prepares by stirring the water system that adds fiber.The pH value of described system transfers to about 2.5-4.0 usually, has acid, for example sulfuric acid, acetic acid or nitric acid.But, higher pH value up to 11.0, is feasible.

Fiber generally is chosen to be diameter less than 5 microns, and general diameter is less than 3 microns.Generally selected 10mm, the 5mm or shorter usually of being not more than of the length of fiber.Usually, the fibre weight scope in the per gallon water is the 4-8 gram.

In order to prepare fibrous matrix, the axle that is connected to vacuum source is immersed in the mud, by the sufficiently long time of vacuum draw, to generate the shaping medium matrix of depth desired on axle.For common commercial technology, (for specific fibrous suspension) specified requirements can be through after a while, or passed through axle up to specific fibrous suspension by suction fully.

Subsequently, axle (still having the vacuum draw and the shaping fiber layer on it that are connected to it) is immersed in the water-resin solution, and by the sufficiently long time of vacuum draw, to use the resin impregnated medium, the described time is generally 5-300 second.

Described axle (still having the vacuum draw and the shaping fiber layer on it that are connected to it), the air that is subjected to then passing therebetween aspirates sufficiently long a period of time, to remove excessive water and resin.The common described time is about 10-200 second.

In manufacturing process, can produce axle and fiber combinations with a vacuum source, described then another vacuum source that is connected is to be used for next procedure; Perhaps, can use identical vacuum source.In addition, fibrous matrix can be removed from axle, and is installed on second axle, but this is not preferred usually.

This matrix that soaks into can separate from axle then, or can stay thereon if necessary, and handles under the various conditions that characterize.Preferred processing method is as described below:

1. for resin the system of epoxy resin or phenolic resins: be not higher than (preferably not being higher than 100 ℃) dry sufficiently long a period of time under 120 ℃ the temperature, to evaporate all excess waters and to condense described resin and do not have the not migration of extend of hope; With, continue to handle to solidify described resin with heating furnace, common in 110 ℃-180 ℃ temperature range, common 150 ℃-180 ℃.Usually, can in heating furnace, handle 5 hours or the shorter time is finished described solidifying.

2. for from any resin in following group: water-based epoxy resin; Water based phenolic resin; Polyurethane and latex:

(a) be no more than room temperature (24 ℃) in environment temperature, preferably be not higher than 10 ℃,, dry sufficiently long a period of time, removing excessive moisture, and condense resin and do not have the not migration of extend of hope more preferably no higher than 0 ℃ and be not higher than usually and preferably under-5 ℃; With

(b) a period of time that next cured resin is suitably grown in heating furnace, usually at least 110 ℃, often 150 ℃-180 ℃.Setting time is generally 5 hours or still less.

In this article, be when carrying out when mentioning drying in a certain temperature or under this temperature, for example be lower than the temperature of room temperature, and do not mean that described element can not be exposed to the higher temperature condition.(for example, in operating usually, described element can be in room temperature when tank takes out.) opposite, this is illustrated in before dry generation of essence and the resin transfer, described element is in before the essence resin transfer under the preferred temperature environment of appointment, condenses in the temperature conditions generation down of qualification to guarantee most of drying time and resin, and does not have the resin transfer of unacceptable degree.In addition, described resin can be the dispersion of bisphenol-A phenolic varnish gum.

IV. gas/the oil eliminator that has medium usually

One type of this separator is the type that generally is used for separate compressors system gas/oil.Usually, described separator is maintainable parts, that is, they can insert and remove from shell in use.Described separator generally comprises following parts: (a) installation component; (b) level of condensing; (c) discharging level.

But the level of condensing and a discharging level one are placed in the separator together, and perhaps they can be assembled respectively but in whole discrete device.In common structure, the level of condensing at least layer can comprise the medium as formation that this paper characterizes.In certain situation, the level of condensing and discharging level all comprise described medium.

Can use polytype structure, comprise following example: the cylinder shape medium structure; Oval dielectric structure; With conical dielectric structure.Medium can form outside to inside the work of flowing or interiorly start building to do to outflow.In the work system that flows outside to inside, the level of generally condensing is around the discharging level.For the mobile outward structure of introversion, general discharging level is around condensing level.This is because in operate as normal, at first is drawn towards the level of condensing by the separator driven air, secondly by the discharging level.

Can use multiple erecting device and medium pack arrangement, comprise being disclosed in U.S.5,605,555; 6,093,231; 6,136,076; WO99/47211; U.S.6,485,535, PCT applies for US03/38822, and the applying date is on December 5th, 2003, and publication No. is WO04/052503, and whole disclosures of these documents are incorporated into this paper at this.

In oil cooling revolving type screw air compressor, fill mist of oil in the compressed air.Compressed air is being released into before service line is supplied to the terminal use, gas/oil eliminator removes from air-flow and deoils.It is the oil content of 2/1000000ths (ppm) by weight that the air that leaves gas/oil eliminator can have usually.The common condition of work that gas/oil eliminator bears is that temperature is that 170-225 (76.7-107.2 ℃) and air pressure range are 60-190psig (4.1-13.1Bar).The performance specification of gas/oil eliminator normally 2ppm oil content leaves separator, and opens the beginning pressure drop for less than 2psid (0.138Bar).

Accompanying drawing 1-3 shows common gas/oil eliminator 40.In use, separator 40 is suspended in the compressed air container, has flange 41 and is clamped by container cover.Compressed air passes this separator 40 to service line.Separator 40 is removed mist of oil from air-flow.For the separator in the accompanying drawing 40, air leads to inside from the outside, although other scheme is feasible.In other words, above-mentioned resin technique for applying can be used for making introversive outer flowing and the medium of flow separation device outside to inside.

The parts that constitute separator 40 in the accompanying drawing are described in following paragraph.

Referring to Fig. 2, show packing ring 49.Two packing rings 49 are connected to separator flange 50 at opposite side usually.Flange 50 can be that metal or plastics are molded directly on the medium; Be illustrated as metal rim.When separator 40 is installed, these packing ring 49 sealing receiving slits.Top packing ring 49a is sealed in and receives between chamber cap and the separator flange 41.Bottom gasket 49b is sealed between the receiving chamber antelabium and separator flange 41 that hangs separator 40.Packing ring 49 can be made of a variety of materials, comprises, for example, rubber, cork, the elastomeric compounds of silicone and similar polyurethane and epoxy resin.In addition, can use the PCT application US03/40691 that is incorporated into this paper at this, the applying date is described molded (mold-in-place) packing ring on the throne in 17 days December in 2003.

Referring to Fig. 3, can use optionally outside sign bag at 58 places.The optional outside sign at described 58 places is wrapped normally high osmosis material, is printed on customer ID.It can be made by polyester or other polymeric material or the cardboard of handling.

In Fig. 2 and 3, show end cap 67.End cap 67 plays a part stopper, thereby air can only be discharged from the outlet opening 68 of flange 41.It also provides container 69, and the oil return apparatus that is used to collect condensation of oil and pass through compressor is removed.End cap 67 has sealant groove 70, and wherein elastomeric material as polyurethane or epoxy resin, is introduced in the sealant groove, with the condense medium tube of level and discharging level of sealing.End cap 67 can be that metal or plastics directly are molded on the medium.Shown in the figure is metal end.

In Fig. 1 and Fig. 2, show flange assembly 41.When flange 41 was not molded directly on the medium, flange assembly 41 comprised sealant groove 41a, and wherein elastomeric material as polyurethane or epoxy resin, is introduced in the sealant groove, with the condense medium tube of level and discharging level of sealing.

In Fig. 2 and Fig. 3, show media set 90.Described media set 90 comprises the level 91 of condensing that is used for gas/oil eliminator 40.Shown example comprises optional outer lining 92, the metal medium support column 93 of fiberglass media 91 and porous.Shown outer lining 92 is perforated plates, but other alternative also is available.Liner 92 is used to provide uniform outer surface, provides outside sign bag around it.Glass medium 91 plays separating medium, and wherein it collects oil droplet, and provides the surface to condense and to increase into amount.It can be the medium according to preparation mentioned above.The support column of porous (central pad) provides support structure to glass medium.

In Fig. 2 and Fig. 3, show dielectric layer 104.This medium 104 is the main discharge medium in the separator.Medium 104 remove leave the level 91 of condensing than larger oil droplet, and they are entered removing container 69 in the end cap 67.It can be by the polyester material of nonwoven, metallic fiber, and the metallic fiber of flocculated glass or other polymeric material, or the glass fibre of combination is made.It can be the medium according to preparation mentioned above.

In Fig. 2 and Fig. 3, can be at 105 place's working medium layers.This medium is used as scrim, drips to catch any fleeing from by entrained oil once more from discharge medium 104.It is also preferably made by spunbond polyester material usually.

In Fig. 2 and Fig. 3, can be chosen in 112 places and use screen cloth.Screen cloth 112 can be made of aluminum, and can be placed in the assembly according to customer requirement.It does not separate the function of oil droplet from air.

Liner 113 has been shown in Fig. 2 and Fig. 3.Described liner 113 is made by the perforated plate pipe, but also can use plastics.It is the support column of discharge medium.

For common example system, the length of separator 40 is approximately 247.6 ± 3mm; The external diameter of flange 41 is about 200.2mm; The external diameter of end cap 67 is about 174.8mm; The internal diameter in hole 68 is about 96.8mm; And medium 90 has the length of about 228.6mm.Metal rim 41 can have the thickness of about 1.63mm, and each packing ring to be about 1.5mm thick.Certainly, also can use different sizes.

For the structure described in the accompanying drawing, also can use multiple other structure.Accompanying drawing is just represented the common parts of separator assembly, the separator assembly of Liu Donging especially outside to inside, the medium that is configured to use according to the present invention and is constructed.For shown in cylindrical, also can use other shape to replace.Equally, as noted above, can use the introversive outer separator that flows.This structure is not used flange 50 usually, and is to use sleeve pipe or similar structures, and for example the applying date is that the document is incorporated into this paper at this shown in the PCTUS 04/38369 on November 16th, 2004.

Two main separating mediums are arranged in separator; Oil is condensed in the level of condensing, and enters the discharging level by gravitational discharge from air-flow.The medium of being made by present disclosed technology and parts can be used for any one or both of above-mentioned two-stage.Compressed air passes the level of condensing, and oily suspended particulates condense and form bigger oil droplet.Bigger oil droplet further condenses in discharging level, and becomes too big and can't be suspended in aerial; They are stayed on the discharging level medium, and the air drain separator that purifies.Accompanying drawing is illustrated in 105 the level of condensing.It comprises the support column of being made by porous metals 113, condensed medium and the outer lining of being made by perforated plate.This is the common gas/oil eliminator in the air compressor internal application.

Condensed medium also can be used for other application, to separate mist of oil from air.It can be used as further the purify air air quality in compressor downstream of filter; This application is called as " axially knockouts " or " using the some knockouts ", is used for the post processing of compressed-air line.They also are separators, but are called as knockouts sometimes.These knockouts are connected to the service line in air compressor downstream.The function of these knockouts is the oil contents that further reduce in the compressed-air line.After compressed air left gas/oil eliminator in the compressor, it entered heat exchanger, here cooling.The compressed air that leaves heat exchanger passes the dewatering system of axial knockouts then, and enters terminal use's service line then.As axial knockouts, medium can with mode effect identical in gas/oil eliminator.Medium can be low temperature more (be generally 160 °F or lower, that is, 71.1 ℃ or lower), with have the situation that littler upstream requires (upstream challenge) under from air, separate mist of oil.Here, the upstream requires normally 2ppm or lower, and wherein in compressor gas/oil eliminator, it may be thousands of ppm that the upstream requires.These axial knockouts have their shell; Gas/oil eliminator is accommodated in the receiving slit of air compressor usually.Some gas/oil eliminators are spun types, so they are accommodated in the jar described jar of head that is swirled to the air compressor pipeline.Axially other difference between knockouts and other separator is how the oil of removing from air line transmits.In gas/oil eliminator as shown in Figure 2, isolated oil is transmitted back to the oil circulating pipe line with pipe.For axial knockouts,,, and there is not the oil return pipeline to air compressor to such an extent as to it often goes out of use because coalescent oil mass seldom.

Generally, according to disclosure of the present invention, provide a kind of gas/oil eliminator (axial knockouts that is used for; Compressor assembly separator or other) dielectric matrix.Described dielectric matrix generally comprises the glass fibre matrix, and it comprises the water-based resin system.

Claims (17)

1. method for preparing gas/oil eliminator, described separator comprises at least the first media stage; Described method comprises the steps:

(a) under the vacuum draw effect, pass the medium bag, with resin impregnated fiber medium bag by aspirating water base resin system;

(b) afterwards, suction air passes through described medium bag under the vacuum draw effect in step (a);

(c) at the further afterwards dry described medium bag of step (b);

(d) by being exposed at least 115 ℃ environment temperature, the resin in the setting medium bag;

(e) described medium bag is included in described gas/oil eliminator.

2. method according to claim 1, wherein:

(a) described water-based resin system is the water-based epoxy resin system, and its content of formaldehyde is not more than 0.001% of total weight of solids.

3. method according to claim 2, wherein:

(a) described under the vacuum draw effect suction air undertaken at least 10 seconds by the step of medium bag.

4. method according to claim 3, wherein:

(a) described suction air is by the step of medium bag under the vacuum draw effect, and its time of carrying out is in 10-200 scope second.

5. method according to claim 4, wherein:

(a) step of described further drying medium bag is carried out in 80 ℃-110 ℃ temperature range.

6. method according to claim 5, wherein:

(a) step of described further drying was carried out 1 hour.

7. method according to claim 5, wherein:

(a) step of described cured resin is carried out being exposed under at least 150 ℃ the temperature.

8. method according to claim 7, wherein:

(a) step of described cured resin was carried out 0.25 hour being exposed under at least 150 ℃ the temperature at least.

9. according to the described method of arbitrary claim among the claim 2-8, wherein:

(a) described water-based epoxy resin system comprises the dispersion of epoxy resin, is selected from mainly to comprise in the following group: the dispersion of liquid bisphenol A epoxide resin; The dispersion of urethane-modified bisphenol A epoxide resin; The dispersion of epoxidised o-cresols novolac resin; The dispersion of the epoxy resin of butadiene-acrylonitrile modification; With their mixture.

10. method according to claim 1, wherein:

(a) described water-based resin system is selected from water-based epoxy resin and water based phenolic resin; With

(b) step of described further drying (c) is carried out being exposed under the environment temperature that is not higher than 110 ℃.

11. method according to claim 10, wherein:

(a) step of described further drying (c) is under the environment temperature that is not higher than 24 ℃ at described medium bag and carries out.

12. method according to claim 11, wherein:

(a) step of described further drying (c) is included under 10 ℃ or the lower environment temperature and carries out drying.

13. method according to claim 12, wherein:

(a) step of described further drying (c) is included under 0 ℃ or the lower environment temperature and carries out drying.

14. method according to claim 12, wherein:

(a) step of described further drying (c) is included under-5 ℃ or the lower environment temperature and carries out drying.

15. method according to claim 1, wherein said water-based resin system comprises the dispersion of bisphenol-A phenolic varnish gum.

16. gas/oil eliminator of making according to the described method of claim 1.

17. gas/oil eliminator of making according to the described method of claim 2.

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